Metal-containing transaction card and method of making the same

ABSTRACT

Metal-containing transaction cards, useful for the purchase of goods and/or services, and methods of making the same are provided. The metal-containing transaction card may have a magnetic stripe, an embedded microchip, a signature panel, a holographic image, or any other feature typically contained on or within a transaction card. The transaction cards have at least one layer of metal with, optionally, other layers of substrates, such as thermoplastic polymers, other metals or adhesives. In addition, the metal-containing transaction card may be anodized, coated, or laser-engraved. Preferably, the metal is titanium or stainless steel.

This is a continuation-in-part of U.S. patent application Ser. No.10/749,006, filed Dec. 30, 2003, now U.S. Pat. No. 7,530,491 whichclaims priority to U.S. Provisional Patent Application Ser. No.60/437,938, filed Jan. 3, 2003.

TECHNICAL FIELD

Metal-containing transaction cards useful for the purchase of goodsand/or services and methods of making the same are provided. Themetal-containing transaction cards may be credit cards, debit cards,check cards, stored-value cards, or any other transaction card.

BACKGROUND

The proliferation of transaction cards, which allow the cardholder topay with credit rather than cash, started in the United States in theearly 1950s. Initial transaction cards were typically restricted toselect restaurants and hotels and were often limited to an exclusiveclass of individuals. Since the introduction of plastic credit cards,the use of transaction cards have rapidly proliferated from the UnitedStates, to Europe, and then to the rest of the world. Transaction cardsare not only information carriers, but also typically allow a consumerto pay for goods and services without the need to constantly possesscash, or if a consumer needs cash, transaction cards allow access tofunds through an automatic teller machine (ATM). Transaction cards alsoreduce the exposure to the risk of cash loss through theft and reducethe need for currency exchanges when traveling to various foreigncountries. Due to the advantages of transaction cards, hundreds ofmillions of cards are now produced and issued annually, therebyresulting in a need for companies to differentiate their cards fromcompetitor's cards.

Initially, the transaction cards often included the issuer's name, thecardholder's name, the card number, and the expiration date embossedonto the card. The cards also usually included a signature field on theback of the card for the cardholder to provide a signature to protectagainst forgery and tampering. Thus, the cards served as devices toprovide data to merchants and the security associated with the card wasthe comparison of the cardholder's signature on the card to thecardholder's signature on a receipt along with the embossed cardholder'sname on the card.

Due to the popularity of transaction cards, numerous companies, banks,airlines, trade groups, sporting teams, clubs and other organizationshave developed their own transaction cards. As such, many companiescontinually attempt to differentiate their transaction cards andincrease market share not only by offering more attractive financingrates and low initiation fees, but also by offering unique,aesthetically pleasing features on the transaction cards. As such, manytransaction cards include not only demographic and account information,but the transaction cards also include graphic images, designs,photographs and security features. A recent security feature is theincorporation of a diffraction grating, or holographic image, into thetransaction card which appears to be three-dimensional. Holographicimages restrict the ability to fraudulently copy or reproducetransaction cards because of the need for extremely complex systems andapparatus for producing holograms.

Administrative and security issues, such as charges, credits, merchantsettlement, fraud, reimbursements, etc., have increased due to theincreasing use of transaction cards. Thus, the transaction card industrystarted to develop more sophisticated transaction cards which allowedthe electronic reading, transmission, and authorization of transactioncard data for a variety of industries. For example, magnetic stripecards, optical cards, smart cards, calling cards, and supersmart cardshave been developed to meet the market demand for expanded features,functionality, and security. In addition to the visual data, theincorporation of a magnetic stripe on the back of a transaction cardallows digitized data to be stored in machine readable form. As such,magnetic stripe readers are used in conjunction with magnetic stripecards to communicate purchase data received from a cash register deviceon-line to a host computer along with the transmission of data stored inthe magnetic stripe, such as account information and expiration date.

Due to the susceptibility of the magnetic stripe to tampering, the lackof confidentiality of the information within the magnetic stripe and theproblems associated with the transmission of data to a host computer,integrated circuits were developed which could be incorporated intotransaction cards. These integrated circuit (IC) cards, known as smartcards, proved to be very reliable in a variety of industries due totheir advanced security and flexibility for future applications.However, even integrated circuit cards are susceptible tocounterfeiting.

As magnetic stripe cards and smart cards developed, the market demandedinternational standards for the cards. The card's physical dimensions,features and embossing area were standardized under the InternationalStandards Organization (“ISO”), ISO 7810 and ISO 7811. The issuer'sidentification, the location of particular compounds, codingrequirements, and recording techniques were standardized in ISO 7812 andISO 7813, while chip card standards were established in ISO 7813. Forexample, ISO 7811 defines the standards for the magnetic stripe which isa 0.5 inch stripe located either in the front or rear surface of thecard and which is divided into three longitudinally parallel tracks. Thefirst and second tracks hold read-only information with room for 79alphanumeric characters and 40 numeric characters, respectively. Thethird track is reserved for financial transactions and includesenciphered versions of the user's personal identification number,country code, currency units, amount authorized per cycle, subsidiaryaccounts, and restrictions.

More information regarding the features and specifications oftransaction cards can be found in, for example, Smart Cards by Jose LuisZoreda and Jose Manuel Oton, 1994; Smart Card Handbook by W. Rankl andW. Effing, 1997, and the various ISO standards for transaction cardsavailable from ANSI (American National Standards Institute), 11 West42nd Street, New York, N.Y. 10036.

The incorporation of machine-readable components onto transactions cardsencouraged the proliferation of devices to simplify transactions byautomatically reading from and/or writing onto transaction cards. Suchdevices include, for example, bar code scanners, magnetic stripereaders, point of sale terminals (POS), automated teller machines (ATM)and card-key devices. With respect to ATMs, the total number of ATMdevices shipped in 1999 was 179,274 (based on Nilson Reports data)including the ATMs shipped by the top ATM manufacturers, namely NCR(138-18 231st Street, Laurelton, N.Y. 11413), Diebold (5995 Mayfair,North Canton, Ohio 44720-8077), Fujitsu (11085 N. Torrey Pines Road, LaJolla, Calif. 92037), Omron (Japan), OKI (Japan) and Triton.

Typical transaction cards are made from thermoplastic materials, such aspolyvinyl chloride (PVC) and polyethylene terephthalate (PET). However,these transaction cards are susceptible to being damaged or destroyed ifexposed to damaging environments. For example, transaction cards may bedamaged if left exposed to the elements for an extended period of time.Moisture and/or sunlight may break down the chemical bonds within thepolymers of typical transaction cards, such that transaction cards leftexposed to moisture and sunlight may become warped, cracked andunusable. In addition, thermoplastic transaction cards may be easilybent or may be broken or cut, thereby damaging the transaction card andrendering it unusable.

A need, therefore, exists for a transaction card that has both strengthand durability. Moreover, a need exists for a transaction card thatwithstands exposure to the elements, such as moisture or sunlight. Aneed further exists for a transaction card that may incorporate thefeatures noted above, such as holograms, signature panels, magneticstripes, microchips, and the like, such that is has both strength anddurability. In addition, a need exists for a transaction card thatovercomes the problems noted above.

SUMMARY

The present invention relates to a metal-containing transaction card anda method of making the same. The transaction card may have a magneticstripe, an embedded microchip, a signature panel, a holographic image,or any other feature typically contained on or within the transactioncard. The transaction card of the present invention has at least onelayer of metal. Preferably, the transaction card of the presentinvention has at least one layer of titanium or stainless steel.

A transaction card and a method of making the same are provided wherebythe transaction card has at least one layer of metal. The at least onelayer of metal provides durability and strength to the transaction card.The one layer of metal may be any metal able to be utilized as atransaction card or incorporated into or within a transaction card.Preferably, the at least one layer of metal is titanium, stainless steelor aluminum.

Further, a transaction card having at least one layer of metal isprovided whereby the transaction card is of a standard size, i.e.,compliant with the International Standards Organization (ISO) fortransaction cards.

In addition, a transaction card having at least one layer of metal mayfurther have other layers that include one or more polymeric materialsor other metal material, such as aluminum and the like.

Still further, a metal-containing transaction card is provided havingfeatures typically contained on or in transaction cards, such asmagnetic stripes, embedded microchips, signature panels, holographicimages, and the like. Moreover, the metal-containing transaction cardmay be printed with indicia, such as via screen-printing or alaser-etching process to uniquely identify the transaction card and/orthe issuer of the transaction card or any other information.

Additional features and advantages of the present invention aredescribed in, and will be apparent from, the detailed description of thepresently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A illustrates a plan view of a front face of a metal-containingtransaction card.

FIG. 1B illustrates a plan view of a back face of a metal-containingtransaction card.

FIG. 2A illustrates a cross-sectional view of a metal-containingtransaction card along line II-II of FIG. 1B.

FIG. 2B illustrates a cross-sectional view of an alternate embodiment ofa transaction card along line II-II of FIG. 1B.

FIG. 2C illustrates a cross-sectional view of another alternateembodiment of a transaction card along line II-II of FIG. 1B.

FIG. 2D illustrates a cross-sectional view of a still further alternateembodiment of a transaction card along line II-II of FIG. 1B.

FIG. 2E illustrates a cross-sectional view of another alternateembodiment of a transaction card along line II-II of FIG. 1B.

FIG. 3 illustrates a flow chart showing a method of makingmetal-containing transaction cards.

FIG. 4 illustrates a flow chart showing an alternate method of makingtitanium transaction cards.

FIG. 5 illustrates another flow chart showing an alternate method oftitanium transaction cards.

FIG. 6 illustrates an alternate flow chart showing a still furtheralternate method of making titanium transaction cards.

FIG. 7 illustrates a still further alternate flow chart showing analternate method of making titanium transaction cards with embossedcharacters, a magnetic stripe and a signature panel.

FIG. 8 illustrates a plan view of a titanium card made by the methods ofmaking the titanium transaction cards.

FIG. 9 illustrates a plan view of an inset fill panel made during themethods of making the titanium transaction cards.

FIG. 10 illustrates a plan view of an embossed titanium card withadhesive disposed in the pockets.

FIG. 11 illustrates a plan view of a titanium card having a fill paneldisposed within a pocket and a magnetic stripe and signature paneldisposed in the other pockets.

FIG. 12 illustrates a cross-sectional view of the titanium card havingthe fill panel disposed within the pocket and a magnetic stripe andsignature panel disposed in other pockets.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

Metal-containing transaction cards and methods of making the same areprovided. The transaction cards may be standard-sized (i.e., about 3⅜inches by about 2¼ inches) or any other size yet still usable as atransaction card. Moreover, the transaction card may have a magneticstripe, an embedded microchip, a signature panel, a holographic image,or any other feature typically contained on or within a transactioncard. The transaction cards have at least one layer of metal, preferablytitanium or stainless steel.

Referring now to the drawings, wherein like numerals refer to likeparts, FIG. 1 illustrates a plan view of a metal-containing transactioncard 1 having a front face 10. The transaction card 1 is composed of atleast one layer of metal that has been flattened into a card shape.Typically metal can be rolled into a sheet. The sheet can then be cut toform individual transaction cards.

Any metal may be utilized as the layer or layers of the transactioncards described herein. Specifically, the metals may include titanium,stainless steel, or aluminum, although any other metal is contemplatedby the present invention. Preferably, the transaction card of thepresent invention comprises titanium.

On the front surface 10 of the transaction card 1 may be indicia, suchas images, graphics, words, or other symbols, that may be printed on thefront surface 10 using conventional printing techniques. Alternatively,the indicia may be laser-etched. A typical laser-etching device forlaser-etching metal, such as titanium or stainless steel, is done by alaser from Virtek Vision International, Inc. Lasers can provide markingof metals such as titanium, stainless steel or aluminum of depths of upto 0.100 inches and as low as about 0.003 inches. A pattern may be lasermarked onto the front face 10 (or the rear surface 20, as describedbelow and illustrated by FIG. 1B).

In addition, the laser-etching of the metal layer, typically titanium,may provide the transaction card 1 with a plurality of colors on one orboth of the faces of the card 1. Specifically, the energy utilized tolaser-etch the metal may allow the metal to recrystallize in such a wayas to be viewable by an individual as being of a specific color orcolors.

In an alternative embodiment, one or both surfaces of the transactioncard 1 may be anodized using conventional anodizing methods, therebyproviding one or both surfaces of the transaction card 1 that may sealedwith an oxide layer thereby protecting the metal and allowing thesurface to be receptive to printing inks or coatings. In addition, theanodizing process may provide a color to one or both surfaces of thetransaction card 1. For example, the anodizing process may comprisetreatment of the surface of the metal with an ionic solution under anelectrical current, which can provide one or both faces of thetransaction card 1 with a color depending on the voltage of theelectricity that is used to anodize the one or both faces of thetransaction card 1.

A coating may be applied to one or both faces of the transaction card 1.Preferably, the coating may be a silane compound thereby providing themetal in the transaction card 1 resistance to scratches, damage,fingerprints, and the like. In addition, a dye or ink may beincorporated into the silane coating thereby providing the transactioncard 1 with a particular color. Typically, the silane and the dye areprovided across one or both surfaces of the transaction card 1.Preferably, the silane coating may be incorporated with a black dyewhereby one or both surface of the transaction card 1 will have a blackappearance. Of course, any other colored coating may be applied to thesurface of one or both faces of the transaction card 1 after one or bothsurfaces of the transaction card 1 are anodized, such as acrylic orpolyethylene terephthalate. In addition, the surface coating may becomprised of a thermoset polymeric material, applied to one or bothsurfaces of the transaction card. The thermoset material may be appliedto the transaction card 1 by coating one or both surfaces of thetransaction card 1 with dry powder of the thermoset material, and bakingthe thermoset material to melt the same and set the material on thesurface of the transaction card 1. Of course, the transaction card 1 maybe provided with no colored coating, thereby providing a metal-coloredtransaction card, whereby the natural color of the metal may beviewable.

FIG. 1B illustrates a rear surface 20 of the transaction card 1 of thepresent invention. Provided on the rear surface 20 may be a magneticstripe 22 that may be applied to the rear surface 20 using conventionalmethods, such as by stamping the magnetic stripe to the transaction card1. Moreover, a signature panel 24 may be provided as well and may alsobe stamped to the transaction card 1 or applied via any otherconventional method. The signature panel allows the owner of thetransaction card to place his or her signature on the transaction card,thereby providing a security feature. In addition, a microchip may beembedded into the transaction card of the present invention. Of course,any other feature may be included on the front surface 10 or the rearsurface 20 of the transaction card 1 as may be apparent to one havingordinary skill in the art.

FIG. 2A illustrates a cross-sectional side view of the transaction card1 along lines II-II of FIG. 1B. As illustrated, the transaction card 1includes at least a first layer 26 of metal. Of course, the transactioncard 1 may comprise two or more layers of metal that are adheredtogether via heat, pressure, and/or adhesive. Preferably, thetransaction card 1 contains at least one layer of titanium or stainlesssteel. The first layer 26 further includes the magnetic stripe 22 andthe signature panel 24 adhered directly to the first layer 26 of metal.Preferably, the total thickness of the first layer 26 is about 30 mils,although other thicknesses of the first layer 26 are contemplated by thepresent invention. The layers illustrated in FIGS. 2A-2E are exaggeratedin thickness to clearly illustrate the structures of the transactioncards described herein.

The transaction card 1 may be stamped, embossed or etched to providetexture, images, alphanumeric characters, or the like. As describedabove, the front or rear surfaces of the transaction card 1 may beprinted or laser-etched to provide indicia, such as graphics, images,text, or any other indicia. In addition, the surface of the first layer26 may be anodized and/or coated with a coating to protect the surfacesof the metal and/or to provide the surface with a color. Moreover, anadhesive (not shown) may be provided for adhering the magnetic stripe 22and the signature panel 24 to the metal of the first layer 26. Further,a microchip (not shown) may be embedded into the first layer 26 of metalto provide smart card capabilities to the transaction card madetherefrom.

FIG. 2B illustrates an alternate embodiment of the present invention ofa cross-sectional view of the transaction card 1 along line II-II ofFIG. 1B. As illustrated, the transaction card 1 includes a metal layer30, and an optional adhesive layer 32 to adhesively secure the magneticstrip 22 and signature panel 24 to the metal layer 30. The adhesivelayer 32 may be laminated, coated, or otherwise applied to the metallayer 30. Preferably, the total thickness of the transaction card 1including the metal layer 30 and the adhesive layer 32, as illustratedin FIG. 2B, is about 30 mils, although other thicknesses arecontemplated in the present invention. Preferably, the metal layer 30 ismade of titanium or stainless steel.

Alternatively, the transaction card does not include an adhesive layer,as illustrated in FIG. 2A, and the magnetic stripe 22 and/or signaturepanel 24, as well as any other feature, is applied directly to one orboth surfaces of the metal layer 30. Alternatively, the transaction card1 may have an adhesive layer (not shown) provided on the front face 10of the transaction card 1 for adhering inks or other printing to themetal layer 30.

The transaction card of FIG. 2B may be stamped, embossed or etched toprovide texture, images, graphics, alphanumeric characters or the liketo the transaction card. As described above, the front or rear surfacesof the transaction card may be printed or laser-etched to provideindicia, such as graphics, images, text, or any other indicia.

FIG. 2C illustrates an alternate embodiment of the present invention ofa cross-sectional view of a transaction card taken along line II-II ofFIG. 1B. In the embodiment illustrated in FIG. 2C, the transaction card1 comprises a core layer 40 of a substrate, such as a thermoplasticmaterial of, for example, PVC, PET copolymer, or other substrate.Further, the core layer 40 has a layer of metal laminated to one or bothsides of the core layer 40. In FIG. 2C, the core layer 40 has a firstmetal layer 42 laminated or otherwise disposed adjacent to a firstsurface of the core layer 40 and a second metal layer 44 laminated orotherwise disposed adjacent to a second surface of the core layer 40.The core layer 40 may be about 18 mils, while each metal layer 42, 44may be about 6 mils to provide a transaction card that is about 30 milsin total thickness. However, the core layer 40 and metal layers 42, 44may be any thickness. Preferably, the metal layers 42, 44 are titaniumor stainless steel.

Provided on the second metal layer 44 may be an adhesive 46 laminated orotherwise applied thereto for providing adhesion for the magnetic stripe22, signature panel 24, or other feature typically included on atransaction card. Alternatively, an adhesive layer (not shown) isprovided on the first metal layer 42 for providing adhesion to inks forprinting purposes, or for any other reason. Alternatively, there is noadhesive layer between the magnetic stripe 22, signature panel 24, orother feature typically included on the transaction card and the firstand/or second metal layers 42, 44.

In addition, the transaction card of FIG. 2C may be stamped, embossed oretched to provide texture, images, graphics, alphanumeric characters orthe like to the transaction card. As described above, the front or rearsurfaces of the transaction card may be printed or laser-etched toprovide indicia, such as graphics, images, text, or any other indicia.

FIG. 2D illustrates a fourth embodiment of the present invention,whereby the transaction card 1, illustrated in a cross-sectional view inFIG. 2D, comprises a first layer 50 of a substrate, such as athermoplastic material of, for example, PVC or PET copolymer, and asecond layer 52 of metal laminated or otherwise disposed adjacent to thefirst layer 50. The first layer 50 and the second layer 52 may havethicknesses that sum to about 30 mils. For example, the first layer maybe about 18 mils and the second layer (of metal) may be about 12 mils.However, the layers may be any other thicknesses. Preferably, the secondlayer 52 of metal is titanium or stainless steel.

The first layer 50 may further include an adhesive 54 to provideadhesion to the magnetic stripe 22, the signature panel 24, or to anyother feature contained on the transaction card 1. Alternatively, noadhesive layer is present.

FIG. 2E illustrates a fifth embodiment of the present invention, wherebythe transaction card 1, illustrated in a cross-sectional view in FIG.2E, comprises a first layer 60 of a metal substrate, such as aluminum,or other metal substrate, and a second layer 62 of a second metallaminated or otherwise disposed adjacent to the first layer 60.Preferably, the second layer 62 is titanium or stainless steel, althoughother metals are contemplated by the present invention. As with thetransaction cards described above, the first layer 60 may have anadhesive layer 64 laminated or otherwise applied thereto for providingadhesion to the magnetic stripe 22 and/or the signature panel 24. Aswith the other embodiment described above, the adhesive may be providedon the second layer as well for providing adhesion to inks for printing,or for other features typically contained on a transaction card.Alternatively, no adhesive layer is present and the magnetic stripe 22and/or the signature panel 24 are adhered directly to the metalsubstrate 60.

The following embodiments described herein and illustrated in FIGS. 3-12relate specifically to transaction cards made from titanium. However, itshould be noted that the present invention should not be limited asdescribed, but should also include embodiments whereby other metals,blends and alloys are utilized.

FIG. 3 illustrates a method 100 of making a metal-containing transactioncard of the present invention, wherein the metal is titanium.Specifically, the method 100 includes a first step 102 of preparing thetitanium to form into transaction cards. Specifically a sheet oftitanium may be prepared that is about 30 mils thick. Typically, thetitanium metal is rolled and flattened to the required thickness.Preferably, the titanium sheet comprises titanium metal that has littleto no magnetic properties, so that the titanium does not interfere withthe magnetic stripe and/or microchip that may be embedded within thetransaction card.

In an anodizing step 104, the titanium sheet is anodized using aconventional anodizing process. Specifically, the titanium may bedisposed in a bath having ions and an electrical current therein toanodize one or both of the faces of the sheet of titanium. As notedabove, anodizing the sheet of titanium can provide one or both faces ofthe sheet of titanium with a colored surface, depending on the currentthat is supplied during the anodizing process, as is apparent to onehaving ordinary skill in the art. Moreover, anodizing oxidizes thesurface of the titanium, thereby sealing and protecting the titanium.

In a coating step 106, a coating is applied to one or both faces of thesheet of titanium to provide one or both faces of the sheet with a colorand to further protect the titanium. Specifically, the coating may be asilane coating having a dye contained therein, wherein the silane iscoated as a layer on one or both faces of the transaction card. Thesilane coating may be applied in a waterless solvent or a water-basedsystem. In addition, other materials that may be coated to one or bothfaces of the transaction card are polyethylene terephthalate andacrylic, although any other coating may be utilized to provide a coatingto protect the titanium and, optionally, to provide a color to the oneor both faces of the transaction card. For example, the coating may bemade from a thermoset material that may be sprayed onto the one or bothsurfaces of the transaction card in powder form. The transaction cardmay then be baked, and the powder may melt to the surface of thetransaction card.

Step 108 illustrates a cutting step whereby the sheet of titanium, whichmay have been anodized and/or coated as described above, may be cut intoindividual transaction card shapes. Common methods of cutting titaniuminclude, but are not limited to, water jet cutting, die cutting, lasercutting or plasma cutting. The goal in cutting the titanium is to easilyand efficiently cut the titanium sheet into transaction card shapeswhile avoiding sharp edges.

After cutting the titanium sheet via step 108, the individualtransaction cards may be laser-engraved via a laser-engraving step 110.The laser engraving may be done via commonly known laser engravingtechniques to provide a pattern in one or both faces of the transactioncard. Moreover, the laser engraving may cut away a coating that may bedisposed on the one or both faces of the transaction card, therebyproviding a visible pattern. For example, if a black coating is appliedto the titanium sheet via step 106, the laser beam may etch a pattern inthe black coating to give a pattern that is not black, but may be metalcolored, or colored in any other way. In addition, the laser beam maymelt the surface of one or both faces of the transaction card, which maycause the titanium to recrystallize when cooled. The recrystallizationmay produce a variety of colors in the surface of one or both faces ofthe transaction card. Preferably, the laser engraving step 110 may beaccomplished via a laser, such as, for example, a YAG laser having awavelength of about 1064 nanometers. Of course, any other laser may beutilized that provides a pattern, a texture or a color to the titaniumas may be apparent to one having ordinary skill in the art.

After laser engraving the transaction card, a magnetic stripe andsignature panel of the transaction card may be applied to thetransaction card via step 112. Typically, the magnetic stripe and thesignature panel are stamped using techniques common in the art of makingtransaction cards. Specifically, the magnetic stripe and signature panelare applied to one or both of the surfaces of the transaction card withthe use of an adhesive that may be applied on one or both surfaces ofthe transaction card. Preferably, the adhesive may be screen-printed toone or both surfaces of the transaction card, although any other methodof applying the adhesive is contemplated by the present invention. Mostmaterials require the use of an adhesive to adhere to one or bothsurfaces of the transaction card. However, certain coatings may allowthe magnetic stripe and the signature panel to be applied without theuse of adhesives. For example, a coating of thermoplastic, such as aflat black vinyl thermoplastic, may be coated onto the card and mayallow the magnetic stripe and the signature panel to be applied to thetransaction card without adhesive. The stamping process may melt thethermoplastic material, thereby allowing the thermoplastic material toadhere the magnetic stripe and/or the signature panel when cooled andsolidified.

After the magnetic stripe and the signature panel have been applied tothe transaction card, the transaction card may be milled via step 114 toprovide a space to apply an embedded microchip for a smart card. Themilling process may be done in a similar manner to conventional plastictransaction cards, but may be accomplished with a boron nitride or boroncarbide tipped machine or other machine able to mill titanium. Inaddition, the transaction card may be milled via a cryo-milling process,in which the mill head is cooled with a stream of liquid nitrogen toensure that the transaction card and/or the mill head does not overheat.Typically, the transaction card may have an area about 20 to about 25mils deep milled from the transaction card to provide a space for amicrochip. The microchip may be applied to the milled area of thetransaction card, and may stay within the milled area due to an adhesivethat may be disposed therein.

After milling the transaction card to embed the microchip therein, thetransaction card may be embossed via an embossing step 116.Specifically, the embossing may be done by subjecting the transactioncard to a high pressure die that may punch a character or a plurality ofcharacters into the surface of the transaction card. The embossing maybe done to provide information on the surface of the transaction cardthat may be readable by an individual or a machine. Specifically, anaccount number or other unique identifier is typically embossed on atransaction card. Preferably, the embossing step 116 may be accomplishedwith an addressograph machine. Of course, other methods of embossing thetransaction card are contemplated, and the invention should not belimited as herein described.

Finally, the transaction card may be encoded via step 118 via anyencoding steps commonly used to encode the transaction cards.Specifically, either or both of the recordable media, such as themagnetic stripe and/or the microchip, may be encoded to provide thetransaction card having information contained therein. The recordablemedia may be read via a magnetic stripe reader or a microchip reader, asmay be apparent to one having ordinary skill in the art.

FIG. 4 illustrates an alternate method 200 of making transaction cardscomprising titanium. The method 200 comprises a first step 202 ofpreparing the titanium by rolling and flattening the titanium into asheet to form into transaction cards. The first step 202 may besubstantially similar to the first step 102 described above with respectto FIG. 3.

After the titanium sheet is prepared via step 202, the titanium sheetmay be cut in a cutting step 204, whereby the sheet of titanium may becut into individual transaction card shapes. For example, the titaniumsheet may be cut via the methods described above with respect to step108 of FIG. 3.

Once the individual transaction cards have been cut from the titaniumsheet, each individual transaction card may be tumbled and cleaned tosmooth any sharp edges via a tumbling and cleaning step 206. It isimportant to ensure that all of the edges are smooth.

After the transaction cards have been smoothed and cleaned, eachtransaction card may be anodized and primed via an anodizing step 208.The anodizing step may be substantially similar to the anodizing step104 as described above with reference to FIG. 3.

After being anodized and primed, each transaction card may be coated andoven cured via a coating step 210. The coating step 210 may besubstantially similar to the coating step 106 as described above withreference to FIG. 3. Each side of each transaction card may be coatedand oven-cured separately in a multi-step process.

After each side of each transaction card is coated and oven-cured, eachtransaction card may be laser engraved via laser engraving step 212,which may be substantially similar to the laser-engraving step 110, asdescribed above with reference to FIG. 3.

Once each transaction card is laser engraved, a primer may be applied toone or both of the surfaces by screen printing the primer via a primingstep 214. The primer may be applied across the entire surface of eachtransaction card, or may be applied precisely where the magnetic stripeand/or signature panels are desired.

After each transaction card is primed, the magnetic stripe and/orsignature panels may be applied via step 216. The magnetic stripe and/orsignature panel may be applied in a substantially similar way asdescribed in step 112, described above with respect to FIG. 3.

After the magnetic stripe and/or signature panels have been applied,each of the surfaces of each transaction card may be laser scored viastep 218 to provide graphics, text and numerals to either or both of thesurfaces of each transaction card.

Once each transaction card has been laser scored to provide graphics,text, numerals and/or other indicia, a microchip may be disposed withinthe transaction card via step 220. For example, the transaction card maybe milled to provide a space in the transaction card for an embeddedmicrochip. The disposing of the microchip into the transaction card viastep 220 may be done in a substantially similar manner as step 114,described above with reference to FIG. 3.

Each transaction card may then be embossed via an embossing step 222,which may be substantially similar to the embossing step 118, asdescribed above with reference to FIG. 3. Finally, each transactioncard's recordable media, such as the magnetic stripe and/or the embeddedmicrochip, may be encoded via an encoding step 224.

In an alternate method 300 of making titanium transaction cardsillustrated in FIG. 5, sheets of titanium are prepared via step 302. Thetitanium sheets may be prepared as described above in steps 102, 104with respect to FIGS. 3, 4, respectively. Specifically sheets oftitanium may be prepared that are about 30 mils thick. In addition,other sheets of titanium may be prepared that are about 15 mils thick,that will be cut into inset fill panels, as described below. Typically,the titanium metal is rolled and flattened to the required thickness.Preferably, the titanium sheets comprise titanium metal that has littleto no magnetic properties, so that the titanium does not interfere withthe magnetic stripe and/or a microchip that may be embedded within thetransaction card.

The 30 mil thick titanium sheets are then cut into individual cards viastep 304. At the same time, the edges of the individual cards may bebeveled to create chamfer edges. Preferably, the chamfer edges may beprepared on both surfaces of each individual card on all four edges ofeach titanium card. Alternatively, the chamfer edges may be prepared ononly one surface of each titanium card, such as on a front surface ofeach titanium card. In addition, at the same time that the chamfer edgesare prepared, a pocket may be milled into each individual card. Thepocket may be milled into a backside of each transaction card at thesame location on the transaction card where the transaction card isembossed to provide characters on the front surface of each transactioncard.

Referring now to FIG. 5, the 15 mil thick titanium sheets may then becut into individual inset fill panels via step 306. The inset fill panelwill fit within the pocket when placed therein with a suitable adhesive.When the inset fill panel is disposed within the pocket with a suitableadhesive, the inset fill panel forms a smooth surface on the backside ofthe titanium card.

Both the titanium cards and the inset fill panels may then be brushedvia step 308 to provide a nice finish on each transaction card.Typically, the brushing is done via known titanium brushing techniquesto provide titanium surfaces having a grain running in the samedirection. The brushing may also create titanium surfaces on eachtransaction card having another pattern.

Both surfaces of each titanium card may be coated via step 310 byphysical vapor deposition (“PVD”) of a coating that may be utilized toboth protect the titanium surfaces and provide a distinctive appearance.Preferably, the coating may be titanium carbonitride, which, when vapordeposited on the surfaces of each titanium card, provides an even andsubstantially black coating to each surface of each titanium card. Onesurface of each fill panel may also be coated by physical vapordeposition. Specifically, the surface of the fill panel that is disposedon the outside of the transaction card when the fill panel is adhesivelydisposed within the pocket should be coated by physical vapordeposition. Other coating techniques may also be utilized to provide thecoating on the titanium card as apparent to one having skill in the art.

Graphics may then be laser etched into the titanium card via step 312.Specifically, the laser etching may etch both the coating and thetitanium to provide the graphics, as described above.

Primer or adhesive material may be applied to the backside of eachtitanium card via step 314 to allow the magnetic stripe and/or thesignature panel to be hot stamped thereon, via step 316. A primermaterial that may be utilized is known as “passport transfer material,”and may be utilized to allow the magnetic stripe and the signature panelto adhere to the titanium and/or the coating applied by physical vapordeposition, as described above. The signature panel and/or the magneticstripe may be substantially similar to or identical to typical magneticstripes and/or signature panels typically utilized in transaction cards.

Each titanium card may then be embossed via step 318. The embossing ofthe characters may be applied on the surface of the titanium within thepocket, such as with an addressograph machine. The embossing is donewithin the pocket so that the embossing may be done in titanium that isthinner than the total thickness of the transaction card. It has beenfound that embossing the characters in thinner titanium is easier, andprovides clearer and more visible characters, without distortion orwarping of the characters or of the transaction card.

The recordable media that may be contained within each titanium card maythen be recorded via step 320. For example, magnetic stripes aretypically disposed on a surface of a transaction card. The magneticstripe disposed on the surface of each titanium card may be encoded viastep 320. In addition, if other recordable media are present, such as anembedded microchip, it may be encoded via step 320.

Each embossed character displayed on the front surface of eachtransaction card may then be “tipped” or sanded or abraded to remove thecoating applied by the physical vapor deposition via step 322. Thisallows each character to obtain a metallic hue that is easily andclearly visible when contrasted with the substantially black coating onthe remainder of the transaction card.

The inset fill panel 360 may then be adhered within the pocket 352 viastep 324. A suitable adhesive may be utilized that adheres the titaniumsurface of the inset fill panel 360 with the titanium surface within thepocket 352 or the coating that may be on the surface of within thepocket 352 by physical vapor deposition. A suitable adhesive is known as“die mount adhesive”, which is a heat activated film.

FIG. 6 illustrates an alternate method 400 of making titaniumtransaction cards. The method 400 is similar to the method 300,described above with respect to FIG. 5. However, the transaction cardmade by the method 400 may have a chamfer edge that is bare. In otherwords, the titanium transaction card may have a coating thereon, such asapplied via physical vapor deposition. However, the chamfer edges mayhave a metallic hue because the coating may be removed at the edges tocreate a transaction card having a metallic “frame” around eachtransaction card.

A first step 402 of preparing the titanium sheets may be similar, if notidentical, to the step of preparing the sheets via step 302 as describedin FIG. 5, above. Step 404 entails applying the coating to the titaniumsheets so that the entire titanium sheets are coated prior to cuttingthe sheets into individual cards and inset fill panels, which is donevia step 406. When cutting each titanium sheet into individual titaniumcards via step 406, each edge of each transaction card may be beveled tocreate the chamfer edges without the coating disposed thereon. Thepocket may also be milled during step 406.

The fill panels are cut from the 15 mil thick titanium sheets via step408. When coating the titanium sheets utilized as the fill panels, onlyone surface of the sheet need be coated via vapor deposition. However,having both surfaces coated by physical vapor deposition does not changethe method described herein.

Each chamfer edge may be brushed and cleaned via step 410 to providesmooth edges having metallic grain running in the same direction.Alternatively, the edges may be brushed to provide patterns in thetitanium on the edges of the transaction cards.

The titanium cards may then be etched to provide graphics via step 412.Primer may be applied to a surface of the titanium transaction cards forthe magnetic stripe and signature panel via step 414. The magneticstripe and signature panel may be applied via step 416. The card may beembossed via step 418. The recordable media may be encoded via step 420.Each embossed character may be “tipped” via step 422, and the fill panelmay be adhered within the pocket via step 424. Each step 412-424 may besubstantially similar to or identical to the steps 312-324, as describedabove with respect to FIG. 5.

FIG. 7 illustrates a still further embodiment of a method of makingtitanium transaction cards 500. Specifically, the method 500 comprises afirst step 502 of machining the titanium into cards with pockets forembossing and application of a magnetic stripe and a signature panel.FIG. 8 illustrates a titanium transaction card 550 comprising anembossing pocket 552 disposed within one or more layers of titanium 554,a signature panel pocket 556 disposed within the titanium 554, and amagnetic stripe pocket 558 disposed within the titanium 554. An insetfill panel 560, as illustrated in FIG. 9, is punched pursuant to step504.

A PVD coating is applied to one or more surfaces of the titaniumtransaction card to provide a surface coating, such as a black surfacecoating, on the one or more surfaces of the titanium transaction cardsvia step 506. The transaction card 550 may have other types of coatingsto provide protection of the titanium or to otherwise protect thetitanium.

PVC, or other suitable adhesive material, is disposed within thesignature panel pocket 556 and/or the magnetic stripe panel 558 via step508. As illustrated in FIG. 10, the PVC material, or other adhesivematerial, forms an adhesive layer 566 within the signature panel pocket556 and an adhesive layer 568 within the magnetic stripe panel 558.

A signature panel and magnetic stripe are hot stamped into the signaturepanel pocket 556 and magnetic stripe pocket 358 via step 510. Thesignature panel 570 and magnetic stripe 572, as illustrated in FIG. 11,are applied over the adhesive layer 566 and adhesive layer 568, disposedwithin the signature panel pocket 556 and magnetic stripe pocket 558,respectively. The adhesive layers 566, 568 provide for adequate adhesionof the signature panel 570 and magnetic stripe 572 to the titanium. Thepockets allow the signature panel 570 and magnetic stripe 572 to remaincoplanar with the surface of the card.

Graphics are laser etched on the PVD coating of the titanium transactioncard 550 via step 512. Characters 562 are then embossed via step 514within an embossing pocket 552. The relative thinness of the titanium inthis area allows embossing to be accomplished easily. Adhesive 564 isthen applied within the embossing pocket 552, typically hot-stamped, sothat the inset fill panel 560 may be adhered within the embossing pocket552 via step 516.

The tips of the embossed characters are then abraded via step 518 toexpose the titanium. This allows the characters to take on a metallichue, which stands out against the black PVD coating of the surface ofthe titanium transaction card.

The magnetic stripe 572 is then encoded, and the transaction cardaccount number may be printed onto the signature panel 570. Finally, theedges and the characters are polished via step 522.

FIG. 12 illustrates a cross-sectional view of the titanium transactioncard 550 illustrated in FIG. 11. Specifically, the titanium transactioncard 550 includes the inset fill panel 560 disposed over the adhesive564 within the embossing pocket 552. The characters 562 are embossedthrough the embossing pocket 552 prior to adherence of the inset fillpanel 560. In addition, the signature panel 570 and magnetic stripe 572are illustrated, adhered to the titanium via adhesive layers 566, 568,respectively. As illustrated, the signature panel 570 and the magneticstripe 572 are coplanar with the surface of the card.

Although the above embodiment of the present invention, illustrated inFIGS. 8-12, shows only an embossing pocket 352, a signature pocket 356and a magnetic stripe pocket 358, any other pocket may be milled, cut orotherwise disposed in one or more surfaces of a metal-containingtransaction card to provide a location for a transaction card feature.For example, a transaction card feature may include, as noted above,signature panels, magnetic stripes, microchips, holographic images, orany other feature providing information and/or security thereon ortherewithin. The present invention should not be limited as hereindescribed with respect to FIGS. 8-12.

It should be noted that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. It is, therefore, intendedthat such changes and modifications be covered by the appended claims.

1. A transaction card comprising: a first surface and a second surface;at least one layer comprising metallic titanium; a pocket disposed inthe at least one layer comprising metallic titanium, wherein the pockethas four side surfaces and a bottom surface; and embossed characterspunched into the transaction card within the pocket and protruding fromthe second surface of the transaction card.
 2. The transaction card ofclaim 1 further comprising an inset fill panel adhered within thepocket.
 3. The transaction card of claim 1 further comprising atransaction card feature disposed within the pocket.
 4. The transactioncard of claim 3 wherein the transaction card feature is selected fromthe group consisting of a signature panel, a magnetic stripe, amicrochip, and a holographic image.
 5. The transaction card of claim 1further comprising an adhesive material disposed within the pocket. 6.The transaction card of claim 1, wherein the at least one layer ofmetallic titanium has a thickness of between about 6 mils and about 30mils.
 7. The transaction card of claim 1, wherein the at least one layerof metallic titanium has a thickness of about 30 mils.
 8. Thetransaction card of claim 1, wherein the pocket is continuous.
 9. Thetransaction card of claim 8, wherein the pocket is disposed across asubstantial portion of the at least one layer.
 10. The transaction cardof claim 1, wherein the layer has a thickness of greater than about 6mils.
 11. The transaction card of claim 1, wherein each of the four sidesurfaces are integral with the bottom surface.
 12. The transaction cardof claim 1, wherein a signature panel is disposed within the pocket, thesignature panel configured to act as a writing surface.
 13. A method ofmaking a transaction card having a first surface and a second surface,comprising the steps of: providing at least one layer comprisingmetallic titanium; and disposing a pocket in the at least one layercomprising metallic titanium, wherein the pocket has four side surfacesand a bottom surface; punching characters within the pocket so as toprotrude from the second surface of the transaction card as embossedcharacters.
 14. The method of claim 13 further comprising the step ofadhering an inset fill panel within the pocket.
 15. The method of claim13 further comprising the step of disposing a transaction card featurewithin the pocket wherein the transaction card feature is selected fromthe group consisting of a signature panel, a magnetic stripe, amicrochip and a holographic image.
 16. The method of claim 13, furthercomprising a transaction card feature disposed with the pocket whereinthe transaction card feature is coplanar with the first surface of thetransaction card.
 17. The method of claim 13 further comprising the stepof disposing an adhesive material within the pocket.
 18. The transactioncard of claim 13, wherein each of the four side surfaces are integralwith the bottom surface.
 19. The transaction card of claim 13, furthercomprising adhering a signature panel within the pocket, the signaturepanel configured to act as a writing surface.
 20. A transaction cardcomprising: a first surface and a second surface; at least one layer ofa metal; and, a pocket disposed in the at least one layer of metal inthe first surface of the transaction card, wherein the pocket has fourside surfaces and a bottom surface; embossed characters punched in thetransaction card; and embossed characters punched in the transactioncard within the pocket and protruding from the second surface of thetransaction card.
 21. The transaction card of claim 20, furthercomprising an inset panel adhered within the pocket.
 22. The transactioncard of claim 21, wherein the inset panel is adhered within the pocketby means of an adhesive.
 23. The transaction card of claim 20, whereineach of the four side surfaces are integral with the bottom surface. 24.The transaction card of claim 20, further comprising adhering asignature panel within the pocket, the signature panel configured to actas a writing surface.